Powerfold actuator for exterior mirror

Abstract

A vehicular exterior rearview mirror assembly includes a mirror head pivotally mounted at a mounting arm configured for attachment at a side of a vehicle. The mirror head includes a reflective element. A powerfold actuator is operable to pivot the mirror head relative to the mounting arm between at least a folded position and a drive position. The powerfold actuator includes a primary detent that is engaged to maintain the mirror head at the drive position when the mirror head is pivoted via the powerfold actuator to the drive position. The powerfold actuator includes a secondary detent. Following pivoting via the powerfold actuator of the mirror head to the folded position, when the mirror head is manually pivoted from the folded position to the drive position, the primary detent is disengaged and the secondary detent is engaged to maintain the mirror head at the drive position.

The invention claimed is: 
     
       1. A vehicular exterior rearview mirror assembly, the vehicular exterior rearview mirror assembly comprising:
 a mounting arm having a first end configured for attachment at a side of a vehicle and a second end distal from the first end; 
 a mirror head pivotally mounted at the second end of the mounting arm, wherein the mirror head comprises a reflective element; 
 a powerfold actuator; 
 wherein the powerfold actuator comprises a housing portion attached at the mirror head and a base portion attached at the mounting arm, the base portion including a base detent that circumscribes a pivot post of the base portion; 
 wherein the powerfold actuator comprises a spring element disposed between an upper detent of an upper detent element and an upper end of the pivot post, the spring element urging the upper detent element toward the base detent of the base portion; 
 wherein the upper detent element is non-rotatably disposed at the pivot post and is longitudinally movable along the pivot post; 
 wherein the housing portion of the powerfold actuator houses an electrically operable motor, and wherein the powerfold actuator, when the electrically operable motor is electrically operated, pivots the mirror head relative to the mounting arm between at least a folded position where the mirror head is along a side of the vehicle and an extended position where the mirror head extends outward from the side of the vehicle; 
 wherein the powerfold actuator comprises an upper detent interface and a lower detent interface; 
 wherein the upper detent interface comprises part of an upper detent of an output gear of the powerfold actuator engaging a correspondingly formed part of a lower detent of the upper detent element; 
 wherein the output gear is disposed between the upper detent of the upper detent element and the upper end of the pivot post, the output gear circumscribing the pivot post; 
 wherein the lower detent interface comprises part of a lower detent of the housing portion engaging a correspondingly formed part of the base detent of the base portion; 
 wherein the powerfold actuator comprises a primary detent that (i) uses the upper detent interface and (ii) uses the lower detent interface to maintain the mirror head at the extended position when the mirror head is pivoted via the powerfold actuator to the extended position; 
 wherein the powerfold actuator comprises a secondary detent that (i) uses the lower detent interface and (ii) does not use the upper detent interface to maintain the mirror head at the extended position when the mirror head is manually pivoted to the extended position; 
 wherein, when the mirror head is manually pivoted from the folded position to the extended position, the primary detent is disengaged and the secondary detent is engaged to maintain the mirror head at the extended position; and 
 wherein, when the powerfold actuator, with the electrically operable motor being electrically operated, pivots the mirror head to engage the primary detent, part of a lower detent of the output gear engages an upper detent of the housing portion. 
 
     
     
       2. The vehicular exterior rearview mirror assembly of  claim 1 , wherein, when the powerfold actuator, with the electrically operable motor being electrically operated, pivots the mirror head between the folded position and the extended position, the lower detent of the housing portion moves along the base detent of the base portion. 
     
     
       3. The vehicular exterior rearview mirror assembly of  claim 2 , wherein, when the powerfold actuator, with the electrically operable motor being electrically operated, pivots the mirror head from the folded position toward the extended position and as the lower detent of the housing portion begins to move along the base detent of the base portion, the housing portion moves upward relative to the base portion to raise the mirror head relative to the mounting arm. 
     
     
       4. The vehicular exterior rearview mirror assembly of  claim 2 , wherein, when the powerfold actuator, with the electrically operable motor being electrically operated, pivots the mirror head between the folded position and the extended position, the upper detent of the output gear moves along the lower detent of the upper detent element and the output gear moves upward relative to the base portion and the upper detent element, and the upper detent element is not raised with the housing portion and the output gear such that the spring element is not compressed further. 
     
     
       5. The vehicular exterior rearview mirror assembly of  claim 4 , wherein the housing portion and the output gear move upward relative to the base portion to provide a gap between the mirror head and the mounting arm as the mirror head is pivoted between the folded position and the extended position. 
     
     
       6. The vehicular exterior rearview mirror assembly of  claim 5 , wherein the housing portion and the output gear move upward at least 1.5 mm relative to the base portion to provide the gap between the mirror head and the mounting arm as the mirror head is pivoted between the folded position and the extended position. 
     
     
       7. The vehicular exterior rearview mirror assembly of  claim 4 , wherein, as the output gear moves upward relative to the base portion, a portion of the upper detent of the output gear is received in a recessed portion of the lower detent of the upper detent element such that the upper detent element is not raised and remains in contact with the base portion. 
     
     
       8. The vehicular exterior rearview mirror assembly of  claim 1 , wherein the powerfold actuator, when the electrically operable motor is electrically operated, pivots the housing portion relative to the output gear. 
     
     
       9. The vehicular exterior rearview mirror assembly of  claim 8 , wherein, when the mirror head is manually pivoted, the output gear and the housing portion pivot together relative to the base portion. 
     
     
       10. The vehicular exterior rearview mirror assembly of  claim 9 , wherein, when the mirror head is manually pivoted, the housing portion and the output gear move upward relative to the base portion and the upper detent element is urged upward against the spring element. 
     
     
       11. The vehicular exterior rearview mirror assembly of  claim 1 , wherein the powerfold actuator comprises a resilient element at the output gear, the resilient element having a radially protruding tab that engages a corresponding tab at the housing portion to limit rotation of the housing portion relative to the output gear to stall the electrically operable motor at stop locations, and wherein the resilient element flexes radially inboard to allow movement of the radially protruding tab of the resilient element to avoid stalling the electrically operable motor at other locations separate from the stop locations. 
     
     
       12. The vehicular exterior rearview mirror assembly of  claim 1 , wherein, when the powerfold actuator, with the electrically operable motor being electrically operated, pivots the mirror head, and when the electrically operable motor is cinched to stop pivotal movement of the mirror head, a spring load path for the spring element is through the output gear, the housing portion and the base portion. 
     
     
       13. The vehicular exterior rearview mirror assembly of  claim 1 , wherein, when the powerfold actuator, with the electrically operable motor being electrically operated, pivots the mirror head, a spring load path for the spring element is directly to the base portion due to the upper detent element engaging the base portion. 
     
     
       14. The vehicular exterior rearview mirror assembly of  claim 1 , wherein the upper detent of the output gear comprises ramped surfaces that movably engage ramped surfaces of the lower detent of the upper detent element, and wherein the lower detent of the housing portion comprises ramped surfaces that movably engage ramped surfaces of the base detent of the base portion, and wherein the lower detent of the output gear comprises ramped surfaces that movably engage ramped surfaces of the upper detent of the housing portion. 
     
     
       15. A vehicular exterior rearview mirror assembly, the vehicular exterior rearview mirror assembly comprising:
 a mounting arm having a first end configured for attachment at a side of a vehicle and a second end distal from the first end; 
 a mirror head pivotally mounted at the second end of the mounting arm, wherein the mirror head comprises a reflective element; 
 a powerfold actuator; 
 wherein the powerfold actuator comprises a housing portion attached at the mirror head and a base portion attached at the mounting arm, the base portion including a base detent that circumscribes a pivot post of the base portion; 
 wherein the powerfold actuator comprises a spring element disposed between an upper detent of an upper detent element and an upper end of the pivot post, the spring element urging the upper detent element toward the base detent of the base portion; 
 wherein the upper detent element is non-rotatably disposed at the pivot post and is longitudinally movable along the pivot post; 
 wherein the housing portion of the powerfold actuator houses an electrically operable motor, and wherein the powerfold actuator, when the electrically operable motor is electrically operated, pivots the mirror head relative to the mounting arm between at least a folded position where the mirror head is along a side of the vehicle and an extended position where the mirror head extends outward from the side of the vehicle; 
 wherein the powerfold actuator comprises an upper detent interface and a lower detent interface; 
 wherein the upper detent interface comprises part of an upper detent of an output gear of the powerfold actuator engaging a correspondingly formed part of a lower detent of the upper detent element; 
 wherein the output gear is disposed between the lower detent of the upper detent element and the upper end of the pivot post, the output gear circumscribing the pivot post; 
 wherein the powerfold actuator, when the electrically operable motor is electrically operated, pivots the housing portion relative to the output gear; 
 wherein the lower detent interface comprises part of a lower detent of the housing portion engaging a correspondingly formed part of the base detent of the base portion; 
 wherein the powerfold actuator comprises a primary detent that (i) uses the upper detent interface and (ii) uses the lower detent interface to maintain the mirror head at the extended position when the mirror head is pivoted via the powerfold actuator to the extended position; 
 wherein the powerfold actuator comprises a secondary detent that (i) uses the lower detent interface and (ii) does not use the upper detent interface to maintain the mirror head at the extended position when the mirror head is manually pivoted to the extended position; 
 wherein, when the mirror head is manually pivoted from the folded position to the extended position, the primary detent is disengaged and the secondary detent is engaged to maintain the mirror head at the extended position; 
 wherein, when the powerfold actuator, with the electrically operable motor being electrically operated, pivots the mirror head to engage the primary detent, part of a lower detent of the output gear engages an upper detent of the housing portion; and 
 wherein, when the powerfold actuator, with the electrically operable motor being electrically operated, pivots the mirror head between the folded position and the extended position, the upper detent of the output gear moves along the lower detent of the upper detent element and the output gear moves upward relative to the base portion and the upper detent element, and the upper detent element is not raised with the housing portion and the output gear such that the spring element is not compressed further. 
 
     
     
       16. The vehicular exterior rearview mirror assembly of  claim 15 , wherein, when the powerfold actuator, with the electrically operable motor being electrically operated, pivots the mirror head between the folded position and the extended position, the lower detent of the housing portion moves along the base detent of the base portion. 
     
     
       17. The vehicular exterior rearview mirror assembly of  claim 16 , wherein, when the powerfold actuator, with the electrically operable motor being electrically operated, pivots the mirror head from the folded position toward the extended position and as the lower detent of the housing portion begins to move along the base detent of the base portion, the housing portion moves upward relative to the base portion to raise the mirror head relative to the mounting arm. 
     
     
       18. The vehicular exterior rearview mirror assembly of  claim 15 , wherein the housing portion and the output gear move upward relative to the base portion to provide a gap between the mirror head and the mounting arm as the mirror head is pivoted between the folded position and the extended position. 
     
     
       19. The vehicular exterior rearview mirror assembly of  claim 15 , wherein, as the output gear moves upward relative to the base portion, a portion of the upper detent of the output gear is received in a recessed portion of the lower detent of the upper detent element such that the upper detent element is not raised and remains in contact with the base portion. 
     
     
       20. The vehicular exterior rearview mirror assembly of  claim 15 , wherein, when the powerfold actuator, with the electrically operable motor being electrically operated, pivots the mirror head, and when the electrically operable motor is cinched to stop pivotal movement of the mirror head, a spring load path for the spring element is through the output gear, the housing portion and the base portion, and wherein, when the powerfold actuator, with the electrically operable motor being electrically operated, pivots the mirror head, the spring load path for the spring element is directly to the base portion due to the upper detent element engaging the base portion. 
     
     
       21. A vehicular exterior rearview mirror assembly, the vehicular exterior rearview mirror assembly comprising:
 a mounting arm having a first end configured for attachment at a side of a vehicle and a second end distal from the first end; 
 a mirror head pivotally mounted at the second end of the mounting arm, wherein the mirror head comprises a reflective element; 
 a powerfold actuator; 
 wherein the powerfold actuator comprises a housing portion attached at the mirror head and a base portion attached at the mounting arm, the base portion including a base detent that circumscribes a pivot post of the base portion; 
 wherein the powerfold actuator comprises a spring element disposed between an upper detent of an upper detent element and an upper end of the pivot post, the spring element urging the upper detent element toward the base detent of the base portion; 
 wherein the upper detent element is non-rotatably disposed at the pivot post and is longitudinally movable along the pivot post; 
 wherein the housing portion of the powerfold actuator houses an electrically operable motor, and wherein the powerfold actuator, when the electrically operable motor is electrically operated, pivots the mirror head relative to the mounting arm between at least a folded position where the mirror head is along a side of the vehicle and an extended position where the mirror head extends outward from the side of the vehicle; 
 wherein the powerfold actuator comprises an upper detent interface and a lower detent interface; 
 wherein the upper detent interface comprises part of an upper detent of an output gear of the powerfold actuator engaging a correspondingly formed part of a lower detent of the upper detent element; 
 wherein the output gear is disposed between the lower detent of the upper detent element and the upper end of the pivot post, the output gear circumscribing the pivot post; 
 wherein the powerfold actuator, when the electrically operable motor is electrically operated, pivots the housing portion relative to the output gear; 
 wherein, when the mirror head is manually pivoted, the output gear and the housing portion pivot together relative to the base portion; 
 wherein the lower detent interface comprises part of a lower detent of the housing portion engaging a correspondingly formed part of the base detent of the base portion; 
 wherein the powerfold actuator comprises a primary detent that (i) uses the upper detent interface and (ii) uses the lower detent interface to maintain the mirror head at the extended position when the mirror head is pivoted via the powerfold actuator to the extended position; 
 wherein the powerfold actuator comprises a secondary detent that (i) uses the lower detent interface and (ii) does not use the upper detent interface to maintain the mirror head at the extended position when the mirror head is manually pivoted to the extended position; 
 wherein, when the mirror head is manually pivoted from the folded position to the extended position, the primary detent is disengaged and the secondary detent is engaged to maintain the mirror head at the extended position; 
 wherein, when the powerfold actuator, with the electrically operable motor being electrically operated, pivots the mirror head to engage the primary detent, part of a lower detent of the output gear engages an upper detent of the housing portion; 
 wherein, when the powerfold actuator, with the electrically operable motor being electrically operated, pivots the mirror head, a spring load path for the spring element is directly to the base portion due to the upper detent element engaging the base portion; and 
 wherein, when the electrically operable motor of the powerfold actuator is cinched to stop pivotal movement of the mirror head, the spring load path for the spring element is through the output gear, the housing portion and the base portion. 
 
     
     
       22. The vehicular exterior rearview mirror assembly of  claim 21 , wherein, when the powerfold actuator, with the electrically operable motor being electrically operated, pivots the mirror head between the folded position and the extended position, the lower detent of the housing portion moves along the base detent of the base portion. 
     
     
       23. The vehicular exterior rearview mirror assembly of  claim 22 , wherein, when the powerfold actuator, with the electrically operable motor being electrically operated, pivots the mirror head from the folded position toward the extended position and as the lower detent of the housing portion begins to move along the base detent of the base portion, the housing portion moves upward relative to the base portion to raise the mirror head relative to the mounting arm. 
     
     
       24. The vehicular exterior rearview mirror assembly of  claim 22 , wherein, when the powerfold actuator, with the electrically operable motor being electrically operated, pivots the mirror head between the folded position and the extended position, the upper detent of the output gear moves along the lower detent of the upper detent element and the output gear moves upward relative to the base portion and the upper detent element, and the upper detent element is not raised with the housing portion and the output gear such that the spring element is not compressed further. 
     
     
       25. The vehicular exterior rearview mirror assembly of  claim 24 , wherein the housing portion and the output gear move upward relative to the base portion to provide a gap between the mirror head and the mounting arm as the mirror head is pivoted between the folded position and the extended position.